Okuma VTM-65 Maintenance Manual 6SK8-H024

6SK8-H024

MAINTENANCE

MANUAL

for

VTM-65

TURNING CENTER OH-FANUC-L (F-18T)

OKUMA & HOWA MACHINERY LTD.

Correct handling of the machine ensures safe and efficient operation. Carefully read through this manual before operating the machine.

This manual describes the correct operating and maintenance procedures to use the machine efficiently. Additionally, the manual describes preparations necessary for operators.

CAUTIONS AND SAFETY ALERT

OH-9708-W-015

I

SAFETY OPERATION

The machine is equipped with such functions as described below for protecting the operator and the machine from being injured or damaged accidentally.

Door with window safe guard Machine main unit

Door open/close interlock Machine main unit

Chuck interlock PMC software Optional

Chuck and tailstock pedal protection cover Machine main unit

X-/Z-stroke end limit switches Machine main unit

Soft limit function

NC parameter

Chuck self-lock cylinder

Machine main unit

Optional

Emergency stop button

Operation panel

Feedhold button

Operation panel

Emergency alarm lamp

Operation panel

Optional

Earth leakage breaker


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II

Optional

Besides the above safety devices, operation should be strictly in con formity with instructions

in this Manual in order to prevent accidents.

Use this machine only after reading and understanding this manual fully. Interpret as

impossible any features/operations which this manual does not describe as possible, and

never attempt them.

Read and understand this Manual carefully before starting operation. Functions and

operations, if not stated in this Manual, should be basically considered "Don'ts".


OH-9708-W-015

III

The machine is equipped with the following warning labels (sign plates) containing signal

words to indicate seriousness of warning, detailed warning messages, or pictographs to

indicate details of seriousness. Signal words and pictographs used on the warning labels are

as shown below. Strictly observe Dos and Donts as stated on the warning labels.

Signal words:

DANGER

Failure to follow the instruction will result in critical bodily injuries or death.

WARNING

Failure to follow the instruction could result in serious bodily injuries or death.

CAUTION

Failure to follow the instruction may result in less serious bodily injuries or machine

damages.

Pictographs:

There is a possibility that the chuck jaws and a workpiece may flip up.

There is a possibility that your fingers or hands may be pinched by the chuck jaws and a workpiece.

There is a possibility that your body or hands may be caught by a machine moving section (doors, tool post, etc.).


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IV

There is a possibility that your body, either partially or wholly, may be caught by a rotating section (chuck, spindle drive pulley, etc.).

There is a possibility of electric shock.


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V

WARNING LABELS

GROSS MAS

WIRE ROPE D


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VI

[12] Warning lavel for ATC


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VII

WARNING LABELS POSTING POSITIONS

[7] W

arni

ng la

bel f

or m

ovin

g pa

rt ha

zard

[5] W

arni

ng la

bel f

or c

huck

jaw

haz

ard

[6] W

arni

ng la

bel f

or d

oor

(O

nly

for

the

mac

hine

with

aut

omat

ic d

oor)

[9] W

arni

ng la

bel f

or

[8

] War

ning

labe

l for

rot

atin

g pa

rt ha

zard

[3

] War

ning

labe

l for

wor

kpie

ce s

pin-

out h

azar

d

[4] W

arni

ng la

bel f

or

sp

indl

e ha

zard

[1] G

ener

al c

autio

n

l

abel

[11]

War

ning

labe

l for

lif

ting

mac

hine

haz

ar

[10]

Mac

hine

num

ber p

late

with

man

ufac

ture

rs n

ame

[2] F

or s

pind

le

O

pera

tion

CONTENTS

CHAPTER 1 MAINTENANCE AND INSPECTION ..................................1-1

1.1 Lubrication Unit ...........................................................................................................1-1

1.2 Hydraulic Oil................................................................................................................1-3

1.3 Coolant........................................................................................................................1-6

CHAPTER 2 CLEANING ......................................................................2-1

2.1 Slide Cover and Wiper................................................................................................2-1

2.2 Limit Switch................................................................................................................2-5

CHAPTER 3 ADJUSTMENT AND REPLACEMENT ...............................3-1

3.1 Pressure Units............................................................................................................3-1

3.2 Tapered Jib for Slideway ............................................................................................3-2

3.3 V-belt ...........................................................................................................................3-4

3.3.1 Belt tension adjustment ......................................................................................... 3-5

3.3.2 Replacement of V-belt................................ ................................ ............................ 3-6

3.4 Leaf Chain...................................................................................................................3-7

3.5 CNC Memory Backup Battery .................................................................................. 3-10

3.6 Absolute Pulse Coder Battery .................................................................................. 3-11

CHAPTER 4 PERIODICAL INSPECTION ..............................................4-1

CHAPTER 5 SPARE PARTS LIST (AT ADDITIONAL COST).........................5-1 5.1 Mechanical Parts ........................................................................................................5-1

5.2 Hydraulic Unit/Pneumatic Unit....................................................................................5-4

5.3 Electrical Parts ...........................................................................................................5-5

5.4 Special Specifications ................................................................................................5-6

CHAPTER 6 APPENDIX.......................................................................6-1

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1-1

CHAPTER 1 MAINTENANCE AND INSPECTION

Lubricant, hydraulic oil and coolant should be properly maintained according to the lubrication control chart (page 1-8) and list of lubricants (page 1-9). Proper lubrication is very important for extending the service life and maintaining the accuracy of the machine. Note: Before lubrication and replenishment, clean around the oil supply port in case dust

is taken in.

1.1 Lubrication Unit

Oil in the tank decreases gradually as the machine is used. It is necessary to add oil when the alarm buzzer sounds and a warning is displayed on the CRT display when the oil level drops below the specified level. Note: A special long-life grease is sealed in the headstock. Therefore, lubrication of

the headstock is generally not needed. The application interval is controlled by the timer and set at approximately 15 minutes to forcibly lubricate the slideway, gear box, and leaf chain (for tool slide balancing) with the automatic intermittent lubrication pump.

Maintenance item 1 2 3 4

Symbol

Inspection (hr.) 8 8

Replenishment (hr.) 200

Cleaning/replacement (hr.) 1000

Replenishment amount (lit.) 4.3 (1.14 gal.)

Type of oil Mobil Vactra Oil No.2 (Mobil Oil)

Remarks Add if necessary. Add if low lubricant level alarm occurs.

Check pressure (0.5 - 1.6 MPa)

Replace suction filter.

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1-2

LUBRICATION UNIT

Cleaning/replacement

(hr.) Maintenance

item Oil Maintenance content

Replenishment of

lubricant [4.3 lit. (1.1 gal.)]

200 1 Mobil Vactra oil No. 2 (Mobil Oil)

? Add if low lubricant level alarm occurs. (Remaining amount: 1.7 lit. (0.45 gal.))

8 2 Mobil Vactra oil No. 2 (Mobil Oil)

Confirmation of oil level

? Add if oil level is low.

8 3

Confirmation of pressure

? 0.5 - 1.6 0.1 MPa

1000 4

Replacement of

suction filter

? Replace suction filter SFC/ZP-20 (Willy Hogel) with new one.

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1-3

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1-4

1.2 Hydraulic Oil

Hydraulic oil in the hydraulic unit should be replaced periodically. Add oil through the oil supply port while checking the oil level on the level gauge. A suction filter and a cartridge filter are provided to protect the pumps and hydraulic equipment. Since the performance of the suction filter cartridge deteriorates over time, clean or replace it every 3 months.

Maintenance item 5 6 7 8 9

Symbol

Inspection (hr.) 8 8


Cleaning/replacement (hr.) 1000 1000

Replenishment amount (lit.) 60 (15.87 gal.)

Type of oil HM32

Remarks Check pressure (4.9 Mpa)

Replace after specified time period.

Add if necessaty.

Replace suction filler.

Replace cartridge filter.

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1-5

HYDRAULIC UNIT

Cleaning/replacement(hr.) Maintenance item Oil Maintenance content

8 5 Confirmation of pressure

? 4.9 MPa

Replenishment of lubricant

[60 lit. (15.87 gal.)]

1000 2 HM 32 or equivalent ? Replace oil after specified

time period.

8 3 HM 32 or equivalent

Confirmation of oil level

? If oil level is below L, add oil.

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1-6

HYDRAULIC UNIT

Cleaning/replacement (hr.) Maintenance item Oil Maintenance content

Replacement of

suction filter

1000 8 ? Replace suction filter

(SFT-06-150W made by Taisei Kogyo) with new ones.

Replacement of

cartridge filter

1000 9 ? Replace cartridge filter

(F-913-1 made by Taisei Kogyo) with new ones.

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1-7

1.3 Coolant

A water soluble emulsion (emulsifier oil) is recommended. Using other types of water soluble coolant may cause the electrical insulation resistance to lower or non-iron metals (especially zinc) to rust. Therefore, careful consideration is needed when selecting the coolant. During the summer, a large amount of water will evaporate. Water should be added periodically to control the concentration of the coolant. When adding only water, always turn ON the coolant pump switch to agitate sufficiently.

Maintenance item 10 11 12

Symbol

Inspection (hr.) 50

Replenishment (hr.)

Cleaning/replacement (hr.) 50

Replenishment amount (lit.) 400 (105.68 gal.)

Remarks Consult sales representative for replacement period.

Add water or coolant depending on coolant density.

Clean if cutting chips have clogged or solidified. Replace if wire netting is damaged or its mesh is damaged.

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1-8

COOLANT TANK

Cleaning/replacement (hr.) Maintenance item Oil Maintenance content

Confirmation of

coolant level

50 11 Emulsion type

? If coolant is not at H level while machine is not operating, add water or coolant according to coolant density.

Cleaning or replacement of filter

50 12

? If the filter clogged with chips, clean the filter (once a week.) Replace if wire netting is damaged or its mesh is deformed.

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1-9

Recommended Oil & Grease

Name No. Part to be lubricated ESSO Shell Mobile oil

Remarks

1 Lubrication unit Vactra Oil No. 2

2 Hydraulic unit Unipower SQ32 Tetora Oil 32 DTE 24

3 Coolant tank Consult sales representative for appropriate coolant since coolant differs depending on workpiece material and tool used for machining.

Emulsion-type coolant is recommended.

4 Lubrication unit (Special specification)

Unipower MP68 Tetora Oil 68 DTE Oil Heavy medium

5 Pneumatic unit Stanol 43N Turbine Oil 32

1-9 O

H-970

8-W-015

LUBRICATION CONTROL CHART

Part to be lubricated Lubrication unit Hydraulic unit Coolant

Number 1 2 3 4 5 6 7 8 9 10 11 12

Symbol

Control item

Inspection (hr.) 8 8 8 8 50


Cleaning/replacement (hr.) 1000 1000 1000 50

Change (hr.) 1000 (1000)

Tank capacity [lit. (gal.)] 6 (1.58) 60 (15.87) 400 (105.68)

Quantity [lit. (gal.)] 4.3 (1.13)

Lubricant type No.1 No.2 No.3

Note 1: Supply oil while the machine is stopped.

Note 2: Clean the lubricating parts befor e oiling.

Note 3: Refer to the list of lubricants on the next page for lubricant types.

1-9 O

H-970

8-W-015

OH-9708-W-015

2-1

CHAPTER 2 CLEANING

2.1 Slide Cover and Wiper

Slide seal and wiper are equipped on each slideway to prevent cutting chips from entering the machine. They should be removed every six months for periodical cleaning. If no coolant is going to be used, clean off all chips and apply lubricant before loading the workpiece.

Disassembly procedure:

First, remove all cutting chips adhering to the machine and clean the area around the machine. Then perform the following procedures.

X-axis wiper:

1. Start the machine by turning on the power to the NFB, and control unit, and by pressing the operation preparation button.

2. Move the turret to the +X stroke end and to approx. 100 mm before the +Z stroke end.

3. Turn off the power to the control unit and NFB in that order. 4. Remove the cover on the left side of the tool slide.

Left side of tool slide

Cover

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2-2

5. Remove the wiper on the left side of the tool slide.

6. Remove the slide cover on the right side of the tool slide.

7. Remove the wiper on the right side of the tool slide.

8. Remove cutting chips sticking to the wiper with compressed air and wipe it with cleaning oil.

9. Apply lubricant to the wiper seals and reassemble it.

10. Confirm that the slide cover moves smoothly and wiper works properly after reassembly.

Note: If the seal on the wiper is cracked

or damaged, replace the wiper with a new one.

Left side of tool slide

Right side of tool slide

Wiper

Wiper Slide cover

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2-3

Z-axis side cover:

1. Start the machine by turning on the power to the NFB, and control unit, and then pressing the operation preparation button.

2. Move the tool slide to the farthest position away from the spindle on both the X- and Z-axes.

3. Turn off the power to the control unit and NFB in that order.

4. Remove the side cover under the tool slide. 5. Remove cutting chips sticking to the slide cover with compressed air and

wipe it with cleaning oil.

6. Apply lubricant to the wiper seals and reassemble it.

7. Confirm that the slide cover moves smoothly and the wiper works properly after reassembly.

Note: If the wiper seal is cracked or damaged, replace the wiper with a new one.

Under tool slide

Slide cover

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2-4

Z-axis wiper:

1. Use the same procedures 1 - 4 for the slide cover.

2. Remove the wiper. 3. Remove cutting chips sticking to the wiper with compressed air and wipe it

with cleaning oil.

4. Apply lubricant to the wiper seals and reassemble it. 5. Confirm that the wiper moves smoothly and properly after reassembly.

Note: If the wiper seal is cracked or damaged, replace the wiper with a new one.

Under tool slide

Wiper

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2-5

2.2 Limit Switch

Limit switches are installed to check the open/close status of the door or to confirm the X- and Z-axes overrun to maintain operational safety. Clean the limit switches every 6 months.

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3-1

CHAPTER 3 ADJUSTMENT AND REPLACEMENT

3.1 Pressure Units

The gripping force of hydraulic chuck is adjusted by the reducing valves located at the lower right of the machine. Turning the knob clockwise will increase the pressure. Adjust the pressure to the required setting while checking it on the pressure gauge.

When a pressure switch (speed specification) is provided to detect a chucking pressure drop, be sure to set the pressure switch, as well after adjustment of the reducing valve.

Pressure adjustment range: 0.5 - 3.4 MPa

Pressure reducing valve knob: Clockwise to increase pressure Counterclockwise to decrease pressure

Lower part of machine front panel

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3-2

3.2 Tapered Jib for Slideway

The optimum gap is provided in the tapered jib on each slideway of the machine. However, the gap may increase over a long period of use. In that case, perform the following procedures to adjust the gap.

Adjustment method:

There is a screw (dot marked) provided for tapered jib adjustment when the wiper is removed (Refer to chapter 2, Cleaning, 2.1, Slide Cover and Wiper for removal of wiper on each axis.)

Left side of tool slide Front

Under tool slide

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3-3

1. Tighten the screw 2 completely.

Axis Tightening torque Applicable tools

X 3.9 Ball driver

Z 23.5 Ball driver + flat ratchet (L = 120)

2. Loosen the screw 2 until it comes into contact with the taper jib. Then turn the screw 2 back by the amount specified in the table on the previous page.

3. Tighten screw 1 to secure the tapered jib.

4. Move the turret using the AXIS FEED switch, while checking that the load

monitor of the feed axis motor shows the following values on the screen. If the value is greatly different from the list, consider the return amount and make adjustment again.

Note: X-axis can be finely adjusted with the upper and lower tapered jibs on the left

side of the R-spindle tool slide, shown in the figure on the previous page.

Axis Feed rate override (%) Load value

100 50 X

200 35

100 70 (up), -30 (down) Y

200 50 (up), -15 (down)

Axes Screw return angle

Upper/Middle 0 X

Lower 90

Z 90

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3-4

3.3 V-belt

The spindle AC motor and spindle are connected by a V-belt. If the V-belt is loose or when replacing the V-belt, adjust the belt tension as shown below. Periodic adjustment of the V-belt tension will extend its service life.

Note: V-belt wears out quickly if it slips during operation. Always check the belt tension before use.

Specifications Belt type Number of belts X(tension)

20-2000min-1 AC 22/30kW 14R-3V-1400 3 bundles 2 belts 4 bundles 2 belts 16mm(0.63")

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3-5

3.3.1 Belt tension adjustment

1. Remove the pulley cover.

2. Loosen the two adjustment bolts. 3. Loosen the four tightening bolts.

4. Push in the direction indicated by the arrow to slacken the belt. 5. After the belt is loose, tighten the adjustment bolts until the slack is removed,

and mark that position.

6. Tighten the adjustment bolts further and secure them when the bolts have been tightened 16 mm (0.63") past the marked position.

7. Lock the adjustment bolts and reattach the pulley cover.

Spindle motor at the back of the machine

Motor bracket

Tightening bolts (4 bolts)

Adjustment bolts (2 bolts)

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3-6

3.3.2 Replacement of V-belt

1. Perform steps 1 - 4 of item 3.3.1, Belt tension adjustment.

2. Disconnect the hydraulic hoses (for chuck clamping and drain) and insert a hard ball and plug into the end of the hydraulic hose so that no oil flows out or air enters.

3. Replace the belt.

4. Tighten the adjustment bolts (mentioned on the previous page) and mark the position where the slack disappears.

5. Perform steps 6 and 7 of item 3.3.1 Belt tension adjustment. 6. Reconnect the hydraulic hose.

Hydraulic cylinder at front of machine

Hydraulic hose (for chuck clamping)

V-belt

Hydraulic hose (for drain)

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3-7

3.4 Leaf Chain

The leaf chain elongates due to wearing of the pins and bushings. First, check the elongation of the chain. If the chain length is more than the permissible length, replace the leaf chain. (Refer to the table below.)

Criteria for replacement of leaf chain

6-link chain 117.72 mm (4.63") Permissible length

10-link chain 196.21 mm (7.72")

Measuring points

Note: Since the leaf chain is located above the column, watch your step when

measuring. Make sure the NFB is turned off during measurement.

OH-9708-W-015

3-8

Replacement methods

Perform the following procedures when replacing the leaf chain.

1. Remove the cover on the far right side of the machine. 2. Turn on the power to the NFB, control unit and OPERATION PREPERATION

BUTTON.

3. Move the tool slide to right before the stroke end in the positive direction along the X-axis (farthest from the spindle).

4. Move the tool slide along the Z-axis so that the position of the hole on the balance weight and the hole on the column are aligned.

5. Secure the balance weight with the weight support bar (round bar) through the column.

6. Move the tool slide at low speed and make sure the leaf chain which suspends the balance weight is not tightened. (We recommend placement of a wedge between the base and the tool slide for safety.)

Far right side of machine (R-spindle)

Weight support bar insertion hole

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3-9

7. Turn off the power. (As soon as the power is turned off, the brake on the Z-axis motor activates.)

8. Replace the old leaf chain with a new one.

9. Install the new leaf chain in the reverse order of steps 1 - 7 above.

How to remove the leaf chain:

While referring to the figure below, remove the split pin, pin and metal fitting of the external link.

Notes: 1. If any part of the leaf chain link is disconnected, use a new split pin when

reconnecting.

2. The end of the split pins should be bent after they are inserted.

77

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3-10

3.5 CNC Memory Backup Battery

l About memory backup battery The control unit CMOS memory stores part programs, offset data, and system parameters.

Since the control unit stores a lithium battery for memory backup, the data in CMOS memory can be retained after the main power is turned off.

The battery is set in the control unit before shipment. The memory backup period ranges up to one year. When the voltage of the battery has dropped, the alarm message "BAT" flashes on CRT (LCD). (Or, a PMC alarm message is given, depending on the model.)

When the alarm occurs, replace the battery as soon as possible within one or two weeks. How long the battery will be available depends on the system configuration. When the voltage of the battery has dropped further, backup will be disabled, and thus memory will be deleted and a system alarm (SRAM parity alarm) will occur.

In such a case, data in memory should be cleared completely and input again after battery replacement.

Replace the battery once a year, irrespective of the occurrence of the battery alarm.

l Battery replacement procedures Use a lithium battery. (Choose a battery type appropriate for the NC model,

referring to Table 1.)

Keep the control unit ON for 30 seconds or more.

Turn OFF the control unit. Disconnect the connector from the battery. (When a battery case is provided,

remove the case.)

Replace the battery. Reconnect the connector. (When a battery case is provided, attach the case to its position.)

Note: Finish steps through within 30 minutes. If the control unit has no battery for a long time, data in memory will be deleted.

Table 1

NC Battery type

FS-15, 16, 18, 15i, 16i, 18i, 20i, 21i A02B-0200-K102

FS-20, 21 A02B-0177-K106

POWER MATE A02B-0188-K111

(When placing an order for batteries, contact FANUC.)

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3-11

3.6 Absolute Pulse Coder Battery

l About absolute pulse coder battery

For a feed axis servo equipped with the absolute value detection function, the servo module CMOS memory stores machine coordinates on feed axes. Since the servo module stores a lithium battery for data backup, the data in CMOS memory can be retained even after the main power is turned off.

The battery is set in the servo module before shipment. The memory backup period ranges up to one year.

When the voltage of the battery has dropped, the following alarm message appears on CRT (LCD). (Or, a PMC alarm message is given, depending on the model.) "307 APC ALARM: n AXIS BATTERY DOWN 1"------------ FS-16/18/21 series

When the alarm occurs, replace the battery as soon as possible within one or two weeks. How long the battery will be available depends on the system configuration, such as the number of feed axes.

When the voltage of the battery has dropped further, backup will be disabled, and thus memory will be deleted and the following alarm will occur. "306 APC ALARM: n AXIS BATTERY ZERO"---------------- FS-16/18/21 series

In such a case, origin point return for feed axes is required after battery replacement. Replace the battery once a year, irrespective of the occurrence of the battery alarm.

l Battery replacement procedures

Use a lithium battery. (Choose a battery type appropriate for the NC model, referring to Table 1.)

Keep the control unit ON for 30 seconds or more. Turn OFF the control unit.

Disconnect the connector from the battery. (When a battery case is provided, remove the case.)

Replace the battery. Reconnect the connector. (When a battery case is provided, attach the case to its position.)

Note: Finish steps through within 30 minutes. If the control unit has no battery for a long time, data in memory will be deleted.

Table 1

NC Battery type

FS-15, 16, 18, 15i, 16i, 18i, 20i, 21i, 20, 21 A06B-6073-K001

POWER MATE A02B-0168-K111

(When placing an order for batteries, contact FANUC.)

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3-12

(Supplemental remarks)

Fig. 1 Backup battery for FS-16/18i series

Fig. 2 Battery for FS-16/18i series

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3-13

Fig. 3 Backup battery for FS-20/21 series

Fig. 4 Backup battery for absolute pulse coder

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4-1

CHAPTER 4 PERIODICAL INSPECTION

Inspection and maintenance

After installation

Regular inspection

Inspection Item B

efor

e st

artin

g op

erat

ion

3 m

onth

s

6 m

onth

s

12 m

on

ths

Eve

ry 6

mo

nth

s

Eve

ry 1

2 m

on

ths

Cle

anin

g an

d

repl

acem

ent

(H) Remarks

Levelness of main unit Check levelness with a level.

Mai

n u

nit

Leaf chain (tool slide, balance weight)

Replace if length of 6 links exceeds 116.01 mm (4.59).

Starting torque for drive unit 0.49 ~ 1.47 Nm

Belt tension (motor - spindle)

Stretches 16 mm (0.62) when no stack is present.

Bolt tightness Headstock (12 places), motor main unit, and motor base Spin

dle

Position coder timing belt tension

Stretch so that there is slight elasticity.

Inclination (parallelism)

Adjust if exceeds 0.020 mm (0.001).

Difference of center height

Adjust if exceeds 0.050 mm (0.001).

To

ol

slid

e

bolt tightness Tool slide, turret

Slideway Cleaning of slide seal and wiper

Check for cracks and damage.

Adjustment of tapered jib

Refer to section 3.2, Tapered Jib for Slideway.

Axi

s fe

ed u

nit

Ball screw backlash

X-axis: OD of tool slide

Z-axis Measure end face of tool slide

Allowable valve: 0.020 mm (0.001)

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4-2


After installation

Regular inspection

Inspection Item

Bef

ore

star

ting

oper

atio

n

3 m

on

ths

6 m

on

ths

12 m

onth

s

Eve

ry 6

mon

ths

Eve

ry 1

2 m

on

ths

Cle

anin

g a

nd

re

plac

emen

t (H

) Remarks

Pressure gauge scale 0.5 ~ 1.6 0.1 MPa

Lubricant amount 200

Type: Mobil Vactra No.2 or equivalent

If low lubricant level alarm occurs, it indicates that 1.7 lit. (0.45 gal.) of lubricant remain in tank.)

Mai

n un

it

Filter replacement 1000

Type: SFC/ZP-20 (Willy Hogel)

Lu

bri

can

t ta

nk

Oil leaking or oozing from piping

Pressure gauge scale 4.9 MPa

Amount of hydraulic oil

Add oil level is below L. (Type: HM32 or equivalent)

Filter replacement

1000 1000

Type: SFT-06-150W (Taisei) Type: F-913-1 (Taisei)

Replacement of hydraulic oil

Type: HM32 or equivalent Oil amount: 60 lit. (15.87 gal.) H

ydra

ulic

un

it

Oil leaking or oozing from piping

Amount of coolant 50

If level is below H while machine is stopped, add water or coolant depending on the concentration.

Cleaning and replacement of filter

50 If chips clog or stick, remove them. If filter mesh is damaged or uneven, replace it.

Axi

s fe

ed u

nit

Coolant replacement

Oil amount: 400 lit. (105.68 gal.) Consult coolant manufacturer for replacement frequency.

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4-3


After installation

Regular inspection

Inspection Item

Bef

ore

star

ting

oper

atio

n

3 m

on

ths

6 m

on

ths

12 m

onth

s

Eve

ry 6

mon

ths

Eve

ry 1

2 m

on

ths

Cle

anin

g a

nd

re

plac

emen

t (H

) Remarks

Pn

eum

atic

un

its

Lubricant amount for automatic door, machine base with chuck air blower (optional)

Add the specified lubricant.

Hig

h vo

ltage

pan

el

Filter replacement

Cleaning of limit switch roller and dog

If roller has hardened or there is uneven wear on roller, replace it. Places where roller and dog are used: Door open/close confirmation switches and overtravel detection switches on X- and Z-axes

Ele

ctri

cal

com

pon

ent

Adjustment of gap between proximity switch and dog

Gap amount; 0.5 - 1 mm (0.02 - 0.04) Places where proximity switch and dog are used; Clamp/unclamp confirmation of tool slide, chuck open/close confirmation (optional) When workpiece is changed, always adjust positions of proximity switches.

OH-9708-W-015

5-1

CHAPTER 5 SPARE PARTS LIST (AT ADDITIONAL COST)

5.1 Mechanical Parts

Machine base, column and cover

Name Type Manufacturer Qty Remarks

1 Leaf chain XE 11105 TSUBAKIMOTO 2 BL634-91 links

2 Polycarbonate XA 11145A Okuma Howa 1 Polycarbonate (t = 12)

3 Window glass XA 11146 Okuma Howa 1 Reinforced glass (t = 6)

4 Window packing A XA 11147 Okuma Howa 2 Black oil resistance rubber (t = 1)

5 Window packing B XA 11148 Okuma Howa 1 Black oil resistance rubber (t = 2)

6 Rubber plate XA 18210(1) Okuma Howa 1 Black oil resistance rubber (t = 3)

7 Liner cover LR 11454(1) Okuma Howa 1 Acrylic plate

8 Ball bearing #6204-ZZ 2 K206-204-200-000

9 Ball bearing #6208-ZZ 8 K206-208-200-000

10 Cam follower CF10-1UUR THK 2 K217-110-612-580

11 Oil gauge KL-120 KYOWA 1 K392-100-034-090

12 Caster NJW75 Okamoto koki 4 For chip pan

Headstock


1 Round belt XC 12121 Okuma Howa 1 271



4 Round belt XF 12106 Okuma Howa 1 477

OH-9708-W-015

5-2

Spindle drive (1250 min-1, AC 22/30 kW)


1 V-belt 5VX-1700( 7 ) MITSUBOSHI 1 set K157-900-111-040

Spindle brake


1 Caliper 62K1-2101 SUMITOMO 2

2 Pad shoe LV12142 SUMITOMO 1 set Additional machining required for LV12143

3 Disc XF12111 Okuma Howa 1

Feed


1 Slide seal XA 6CK1-3102 NITTA 1 set

2 Slide seal XB 6CK1-3103 NITTA 1 set (XE13121)

3 Slide seal ZA 6DK1-3102 NITTA 1 set

4 Slide seal ZB 6DK1-3103 NITTA 1 set

5 Oil seal

(for Needle bearing) OS 40504 IKO 4 K218-140-504-010

6 Oil seal SC 50689 NOK 4 K382-200-050-110

OH-9708-W-015

5-3

Tool slide


1 Round belt XE 14116 Okuwa Howa 1

2 Spring* XE 14509 Okuwa Howa 1

3 Spring* MC 50342(1) Okuwa Howa 2

4 Roller bearing N1011BTCG5P4 NSK 1 12K2-0307

5 Angular bearing 7018ATYDBBC8P4 NSK 1 50K2-2132

6 Rotally joint* 532,3,0,5733E Willy hogel 1 12K1-2302-2

7 Belleville spring MC-K-40 Tokai bane 1 19K1-4339

8 Collet BT50-MAS-2 RIKEN 1 15K1-0302

9 Quad ring 4446-366Y Xsel Captain Industries 2 K380-600-215-190

10 Precision belleville spring TS-50 Tokusyu Seiko 16 ZL3-050-000-99

11 Dust Seal DSI 28406 NOK 1 ZX4-0280-00-99

12 U-packing USH 283555 NOK 1 ZX6-0280-00-99

13 U-packing USH 45556 NOK 1 ZX6-0450-00-99

14 O-ring P7 NOK 1 YC4-100-07

15 O-ring P 12 NOK 2 YC4-100-012

16 O-ring* P 14 NOK 1 YC4-100-014

17 O-ring* P 16 NOK 1 YC4-100-016

18 O-ring* P 26 NOK 1 YC4-100-026

19 O-ring P 34 NOK 2 YC4-100-034

20 O-ring P 35 NOK 1 YC4-100-035

21 O-ring P 36 NOK 1 YC4-100-036

22 O-ring P 110 NOK 1 YC4-100-110

23 O-ring P 225 NOK 1 YC4-100-225

24 O-ring G 40 NOK 1 YC4-200-040

25 O-ring G 60 NOK 1 YC4-200-060

26 O-ring G 115 NOK 1 YC4-200-115

27 O-ring G 200 NOK 1 YC4-200-200

28 O-ring G 210 NOK 1 YC4-200-210

29 O-ring G 230 NOK 1 YC4-200-230

30 O-ring G 280 NOK 2 YC4-200-280

*:Spindle through specification

OH-9708-W-015

5-4

Filter


1 Filter A XA 18254 Okuma Howa 1 for coolant tank

2 Filter B XB 18205 Okuma Howa 1 for coolant tank

3 Filter C XB 18206 Okuma Howa 1 for coolant tank

4 Suction filter SFC/ZP-20 WILLEY HOGEL 1 for lubrication tank

5.2 Hydraulic Unit/Pneumatic Unit

Hydraulic unit


1 Strainer SFT-06-150W TAISEI 1

2 Check valve CN-T03-1-10 NACHI 1

3 Return filter CF-06-10m TAISEI 1 Cartridge type: F-913-1

4 Air breather FA-50 TAISEI 1

5 Reducing valve OG-G01-P1-20 NACHI 1

6 Module type 2-pressure reducing valve

OGS-G01-P1C-K-D2-21 NACHI 1

7 Flow regulator OCY-G01-A-Y-20 NACHI 1

8 Solenoid valve SA-G01-E3X-D2-10 NACHI 1

9 Solenoid valve SA-G01-A3X-D2-10 NACHI 3

10 Reducing valve OG-G01-PB-K5544A NACHI 1 Standard hydraulic chuck

11 Solenoid valve SA-G01-E3X-D2-10 NACHI 1 Standard hydraulic chuck

Pneumatic unit


1 FR unit AW3000-03BDG SMC 1

2 FR unit AF4000-04D SMC 1

3 Exhaust cleaner AMC320-03BD SMC 1

4 Solenoid valve VS7-6-FJG-D-3Z SMC 1

5 Solenoid valve VP544-5DZ-A SMC 2

6 Coolant valve AB41-03-5B2HB-DC24V CKD 1

7 Check valve 2232B3SS Japan Controls 1

8 Lubricator AL4000-04B SMC 1

9 Gap sensor 616JX2-LDC ASAHI 1

OH-9708-W-015

5-5

5.3 Electrical Parts

Fuses for AI of NC power supply (A02B-0120-K102)

Name Type Qty Remarks

1 Fuse (7.5 A) A60L-0001-0245 # GP75 4 F1,2

2 Fuse (3.2 A) A60L-0001-0075 # 3.2 2 F3

3 Fuse (5.0 A) A60L-0001-0046 # 5.0 2 F4

4 Fuse (0.3 A) A60L-0001-0290 # LM03 2 F5

Fuses for power supply module (A06B-6077-K250)


1 Fuse (2.0 A) A60L-0001-0245 # 2.0 2 Short-circuit protection of 200 Vac for cooling fan

2 Fuse (5.0 A) A60L-0001-0359 2 Short-circuit protection of 200 Vac for control power

Fuse for servo amplifier module (A06B-6073-K250)


1 Fuse (3.2 A) A60L-0001-0290- # LM32C 2 Short-circuit protection of 200 Vdc for control power

Feed axes


1 Limit switch SL1-A (X axis) Honeywell 2 4 years (8 hrs./day)

2 Limit switch SL1-D (Z axis) Honeywell 2 4 years (8 hrs./day)

Turret


1 Proximity switch E2E-X3D1-N OMRON 2 4 years (8 hrs./day)

Work light


1 Fluorescent light AC100V 20W,50/60 Hz 2 1 year (8 hrs./day)

Control panel


1 Relay LY2N DC24V 3 1 year (8 hrs./day)

2 Relay G2A-432A-N DC24V 2 1 year (8 hrs./day)

3 Relay G2R-1-S DC24V 1 1 year (8 hrs./day)

4 Relay C2A-232A DC24V 1 1 year (8 hrs./day)

5 Power printed circuit board PC6/PC13902 2 1 year (8 hrs./day)

OH-9708-W-015

5-6

5.4 Special Specifications

Chuck high / low pressure changeover


1 Module type 2- pressure reducing valve

OGS-G01-PCC-K-D2-21 NACHI 1


Auto door (pneumatic)



Chuck air blower



APC pallet clamp (hydraulic)



APC pallet clamp (pneumatic)



2 Pressure switch ISE4B-01-65 SMC 1

3 Air regulator AR2000-02BG SMC 1

APC shutter (pneumatic)



OH-9708-W-015

5-7

ATS (Pneumatic)


1 Solenoid valve VS7-6-FJG-D-3N SMC 1 K437-005-008-040

2 Solenoid valve VS7-6-FPG-D-3N SMC 1 K437-005-010-040

3 Silencer AN300-03 SMC 2 K408-300-001-040

* Excluding automatic door type

ATS


1 Stopper bolt LP29134 Okuma Howa 1

2 Slide seal XA19219 Okuma Howa 1 Additional machining to SH-8(NITTA)

3 Ball spline 6DK1-3205 Okuma Howa 1

4 Shock killer SCK-00-06 CKD 2 K195-020-006-090

5 Linear bush LM16UU THK 2 K293-516-837-080

6 LM guide HSR30R2UUC-1-840LH-2 THK 1 set K296-984-084-480

7 Hex. socket head set screw IKO 1 YT6-012-050

OH-9708-W-015

6-1

CHAPTER 6 APPENDIX

X-AND Z-AXES GEARING DIAGRAM

X-axis

Rapid traverse rate: 18 m/min. (708.7 in./min.) AC servo motor Model a22

Ball screw 40 (1.57") lead 12 mm (0.47") (12 mm/motor revolution)

Z-axis

Rapid traverse rate: 20 m/min. (787.4 in./min.) AC servo motor Model a22B

Ball screw 50 (1.97") lead 16 mm (0.63") (16 mm/motor revolution)

OH-9708-W-015

6-2

OH-9708-W-015

6-3

19

18

17 Pressure gauge GV55-323-5MK-TM 1 Nachi

16 Pressure switch Herion 0882100 1 Taiyo

15 Solenoid valve SA-G01-A3X-D2-10 2 Nachi

14 Module 2-pressure reducing valve OGS-G01-P1C-K-D2-21 1 Nachi

13 Base MOB-01X-B2-10 1 Nachi

12

11 Solenoid valve SA-G01-E3X-D2-10 1 Nachi

10 Sub plate MSA-01Y-10 1 Nachi

9

8 Flow regulator OCY-G01-A-Y-20 1 Nachi

7 Solenoid valve SA-G01-A3X-D2-10 1 Nachi

6 Solenoid valve SA-G01-E3X-D2-10 1 Nachi

5 Pressure gauge OPG-D-PT1/4-39x70 1 ASK Corporation

4 Reducing valve OG-G01-P1-20 1 Nachi

3 Base MOB-01Y-W2-10 1 Nachi

2

1-8 Oil level gauge KLA-100A 1 Kyowa

1-7 Oiling port & air breather FA-50 1 Taisei Kogyo

1-6 Pressure gauge GV50-173-100K (10Mpa) 1 Nagano Keiki

1-5 Return filter CF06-10m 1 Taisei Kogyo

1-4 Check valve CN-T03-1-10 1 Nachi

1-3 Uni pump UVD-11A-A3-A3-2.2-4-22 1 Nachi

1-2 Strainer SFT-06-150W 1 Taisei Kogyo

1-1 Oil tank OH Standard 60lit. 1 Maker

1 Hydraulic unit 6FK3-6102-1 1 set Nachi

No. Name Type Qty Manufacturer

OH-9708-W-015

6-4

OH-9708-W-015

6-5

OH-9708-W-015

6-6

PNEUMATIC CIRCUIT DIAGRAM

(3)

ATS (special specifications)

YV[SOL]-45 ATS shutter OPEN

YV[SOL]-44 ATS shutter CLOSE

YV[SOL]-33 ATS backward

YV[SOL]-32 ATS forward

5 Speed controller AS2201F-01-06S 4 SMC

4 Solenoid valve VS7-6-FPG-D-3Z 1 SMC

3 Solenoid valve VS7-6-FJG-D-3Z 1 SMC

2 Silencer AN300-03 1 SMC

1 Manifold VV712-02R-03D 1 SMC

No. Name Model Qty Manufacturer

ATS Shutter ATS

OH-9708-W-015

6-7

OH-9708-W-015

6-8

OH-9708-W-015

6-9

OH-9708-W-015

6-10

1250min-1, AC22/30 kW 5VX-1500 (7)

OH-9708-W-015

6-11

OH-9708-W-015

6-12

OH-9708-W-015

6-13

OH-9708-W-015

6-14

OH-9708-W-015

6-15

OH-9708-W-015

6-16

OH-9708-W-015

6-17

OH-9708-W-015

6-18

OH-9708-W-015

6-19

OH-9708-W-015

6-20

OH-9708-W-015

6-21

OH-9708-W-015

6-22

OH-9708-W-015

6-23

6-2 O

H-970

8-W-015

HYDRAURIC CIRCUIT DIAGRAM

Brake ON

Spindle brake ON 2

Spindle half brake ON

Spindle brake ON

Pallet unclamp

Pallet clamp

Tool unclamp

Tool slide lift

Pressure setting

Hydraulic unit

ATC Magazine

Pressure setting

Pressure setting

Lower Spindle brake Spindle brake

Spindle brake

Pallet clamp

Tool slide

Tool slide lift Tool clamp

Pressure setting

150-mesh Oil tank [60 lit. (15.87)]

6-4

OH

-9708-W

-015


(1)

ATC Shutter Auto door

(Special Specifications) APC shutter

(Special Specifications) SP(PS)-11 Source air pressure YV(SPL)-27 shutter OPEN YV(SPL)-26 shutter CLOSE YV(SPL)-14 door OPEN YV(SPL)-13 door CLOSE YV(SPL)-229 ATC shutter OPEN YV(SPL)-228 ATC shutter CLOSE YV(SPL)-96 C-axis auxiliary

10 9 8 Speed controller AS2211-F-02-10S 2 SMC 7 Solenoid valve VS7-6-FJG-D-3Z 1 SMC 6 5 Pressure switch IS300-02L5 1 SMC 4 Exhaust cleaner AMC320-03B 1 SMC 3 Manifold VV714-03R-03B 1 SMC 2 FR unit AW3000-03BDG 1 SMC 1 Handle cock TN400-3/8 1 KITAZAWA

NO. Name Type Qty Manufacture

17 16 15 Speed controller AS2211-F-02-10S 2 SMC 14 Solenoid valve VS7-6-FJG-D-3Z 1 SMC 13 12 Speed controller AS2211-F-02-10S 2 SMC 11 Solenoid valve VS7-6-FJG-D-3Z 1 SMC NO. Name Type Qty Manufacture

Pneumatic circuit diagram (3)

ATC Magazine

6-5

OH

-9708-W

-015


(2)

Chuck air blow (Special Specifications)

Pallet clamp (Special

Specifications) Tool air blow

SP(PS)-26 Pallet clamp

12

11 Gap sensor 616J2-LDC 1 ASAHI

10 Air regulator AR2000-02BG 1 SMC

9

8 Speed controller AS3211-F-03-06S 3 SMC

7 Solenoid valve VS544-5DZ-A 1 SMC

6

5 Solenoid valve VP544-5DZ-A 1 SMC

4

3 Manifold VV3P5-41-041-03 1 SMC

2 FR unit AF4000-04BD 1 SMC

1 Handle cock TN400-1/2 1 KITAZAWA

NO. Name Type QTY Manufacture

19 Gap sensor 616J2-LDC ASAHI

18 Solenoid valve VP544-5DZ-A SMC

17 2

16 Solenoid valve VP544-5DZ-A 1 SMC

15

14 Check valve 2232B-3SS 2 JAPAN Controlls

13 Coolant valve AB41-03-5B2HB-DC24V 1 CKD

NO. Name TYPE Qty Manufacture

Motor cooling Turning holder seating check

Turret high-pressure

Turret

(Special Specifications)

6-11 O

H9706

-W-013

12 Elbo SLC03-000J 3

11 Take-out block PT3/8, PT3/4 1 Kyowa

10 Radiator C013-200-138 2

9 Bushing BUT3/4 1/4 1

8 Oil level gauge KL-100A 1 Kyowa

7 Check valve CN-T03-1-10 1 Taisei

6 Pressure gauge GV50-173-100K-1500P.S.I 1

5 Uni pump 11VD -1A-A3-15-4-22 1 Fujikoshi

4 Return filter CF-0610 m 1 Taisei

3 Air breather FA-50 1 Taisei

2 Strainer SFT-06 150W 1 Taisei

1 Oil tank 60 lit. 1 Tokiwa

50 Hz 60 Hz

200 V 8.8 A 8.4 A

220 V 8.0 A

Specifications

Pressure 50kg/cm 2 (pressure gauge should be indicated in green.)

Power AC-200 V 50/60 Hz

Hydraulic oil ISO VG32 (90 turbine or equivalent )

Noise Below 70dB

Carting Urethane inside the tank, Lacquer primer outside

Oil temperature Room temperature below + 30 C (Target: below 25 C)

Hydraulic circuit diagram

Pump performance data

2 -RC/4(With bushing 1/4 -3/4)

Drain port

6-13

OH-9708-W

-015

1. The suction filter Type SFT is built in a tank and used for ordinary hydraulic oil. 2. The filter is a stainless wire mesh type. 3. Filtration accuracy : 60, 100, 150, 200 (standard)

n Parts list

5 Metal mesh SUS 1 4 Inner tube SECC 1 3 End plate (lower) SECC 1 2 End plate (upper) SECC 1 1 Connector SS 1 No. Name material Q'ty Remarks

n Dimensions and standard flow rate Model Symbol

Diameter (d) fD B L t1 tl Weight (kgf) Standard f low r a t e

( l i t /min)

SFT -0 2 P T (RC) 1/ 2 19 45 9 0.065 10 SFT -0 3 P T (RC) 1 /4 22 46

36 10 0.07 18

SFT -0 4 P T (RC) 1 /2 27 71 12 0.095 30 SFT -0 6 P T (RC)1/4

63

32 72 59 13 0.1 45

SFT -0 8 P T (RC) 1 82 41 85 71 14 0.19 90 SFT -1 0 P T (RC) 1 1/2 104 50 87 71 0.3 150 SFT -1 2 P T (RC) 1 1/2 55 97.5 81.5

16 0.39 205

SFT -1 6 PT (RC) 2 124 70 130 110 20 0.56 320 SFT -2 0 PT (RC) 2 1/2 85 150 22 0.78 550

SFT- 24 PT (RC) 3 147

100 152 128

24 0.96 730

Indication of Type Filter type : SFT- 06 150

SFT Diameter Filtration accuracy

Symbol Diameter

02 PT (RC) 1 /4

03 PT (RC) 3 /8

04 PT (RC) 1 /2

06 PT (RC) 3 /4

08 PT (RC) 1

10 PT (RC)1 1 / 4

12 PT (RC)1 1 / 2

16 PT (RC) 2

20 PT (RC) 2 1 / 2

24 PT (RC) 3

Symbol Fitration accuracy Material

60W 60 mesh Wire mesh (SUS)

100W 100 mesh

150W 150 mesh

200W 200 mesh

Indication example : SFT- 03- 150W

Table of Flow ISO VG32 Viscosity : 32cst (40C)

6-5 H

L35/35L/9710/W-031

Documents

Okuma VTM-65 Maintenance Manual 6SK8-H024